Filaments with improved luster

ABSTRACT

Various implementations of yarns and multi-component filaments having a plurality of solid particles dispersed throughout a portion of the filaments are described herein. Inclusion of solid particles through a portion of the filaments allows for differing certain properties in products formed from the filaments while maintaining desirable physical properties such as strength or abrasion resistance. For example, including translucent or transparent particles, such as glass flakes or mica, may differ the visual properties, such as providing an increased luster. And, in other implementations, opaque solid particles may be included through a portion of the filaments to create a different property for a product formed with the filament.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.63/116,334, filed Nov. 20, 2020, the content of which is incorporatedherein by reference in its entirety.

TECHNICAL FIELD

This disclosure relates to polymeric filaments, and more particularly tomulti-component filaments with enhanced luster that may find use in theproduction of yarns.

BACKGROUND

Within the textile industry, and particularly the carpet industry,consumers increasingly demand products that show more interesting andcomplex visual properties. The luster of the filaments used inmanufacture is one property that impacts the visual aspect of textileproducts. Typically, manufacturers adjust the luster properties of afilament by adjusting the composition or shape of the filament. Whileproducts having a higher luster may be desirable for their visualproperties, they may be considered impractical in some applications dueto their propensity to more readily show soiling compared to more matteproducts. In many applications, a delusterant such as titanium dioxidemay instead be added to provide a more matte finish to the product.Further, many filaments that naturally have higher luster, such as silk,are also more prone to wear from use. Thus, there is a clear need fornew products for use in textiles that show enhanced luster while alsoshowing enhanced strength and stain resistance properties.

SUMMARY

The present disclosure provides yarns and multi-component filamentshaving a plurality of solid particles dispersed throughout a portion ofthe filaments. Inclusion of solid particles through a portion of thefilaments, in particular translucent or transparent particles such asglass flakes or mica, allow for differing visual properties in productsformed from the filaments, such as an increased luster, whilemaintaining desirable physical properties such as strength or abrasionresistance.

According to a first aspect, a multi-component filament is providedcomprising a first component comprising a first polymer and a secondcomponent comprising a second polymer and a plurality of solid particlesdispersed within the second polymer, wherein the second component formsat least 50 percent of an external (or outermost) surface area of themulti-component filament. In some embodiments, the multi-componentfilament is a bicomponent filament.

In some embodiments, the first component comprises a core and the secondcomponent comprises a sheath, wherein the sheath encapsulates the core.

In some embodiments, the solid particles are evenly dispersed in thesecond polymer.

In some embodiments, the first component may further comprise aplurality of solid particles dispersed in the first polymer, theplurality of solid particles having a concentration by volume in thefirst polymer that is less than a concentration by volume of theparticles of the second polymer. In some embodiments, the solidparticles are evenly dispersed in the first polymer.

In some embodiments, the solid particles may be transparent ortranslucent. In some embodiments, the solid particles may comprise glassflakes. In some embodiments, the glass flakes have an average particlediameter ranging from 5 microns to 35 microns. In some embodiments, theglass flakes have an average thickness ranging from 0.5 microns to 8microns. In some embodiments, the glass flakes are surface treated witha coating, for example a silane coating. In some embodiments, the glassflakes may be present in a concentration of at least 10% by volumewithin the second polymer.

In some embodiments, a luster of the multi-component filament is higherthan that of a multi-component filament that comprises the first polymerand the second polymer without the solid particles.

In some embodiments, the first polymer and the second polymer aredifferent polymers. In some embodiments, the first polymer and thesecond polymer are the same polymer. In some embodiments, the firstpolymer and the second polymer may each be independently selected from apolyamide (for example, polyamide 6 or polyamide 6,6), a polyester (forexample, polyethylene terephthalate or polytrimethylene terephthalate),or a polyolefin (for example, polyethylene or polypropylene).

According to a second aspect, a yarn is provided comprising a pluralityof multi-component filaments as described herein.

According to a third aspect, a yarn is provided comprising at least oneof a first filament and at least one of a second filament, wherein thefirst filament comprises a first polymer, and wherein the secondfilament comprises a second polymer and a plurality of solid particlesdispersed within the second polymer.

The details of one or more embodiments of the disclosure are set forthin the accompanying drawings and the description below. Other features,objects, and advantages of the disclosure will be apparent from thedescription and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Example features and embodiments are disclosed in the accompanyingdrawings. However, the present disclosure is not limited to the precisearrangements shown, and the drawings are not necessarily drawn to scale.

FIG. 1 illustrates a perspective view of an elongated filament accordingto one embodiment.

FIG. 2 illustrates a cross-sectional view of a filament according toanother embodiment.

FIG. 3 illustrates a cross-sectional view of a yarn according to oneembodiment.

FIG. 4 illustrates a cross-sectional view of a filament according to oneembodiment.

FIG. 5 illustrates a cross-sectional view of a filament according toanother embodiment.

FIG. 6 illustrates a cross-sectional view of a filament according toanother embodiment.

FIG. 7 illustrates a cross-sectional view of a filament according to oneembodiment.

FIG. 8 illustrates a cross-sectional view of a filament according toanother embodiment.

FIG. 9 illustrates a cross-sectional view of a filament according toanother embodiment.

FIG. 10 illustrates a cross-sectional view of a filament according toanother embodiment.

FIG. 11 illustrates a cross-sectional view of a filament according toanother embodiment.

FIG. 12 illustrates a cross-sectional view of a filament according toanother embodiment.

FIG. 13 illustrates a cross-sectional view of a filament according toanother embodiment.

FIG. 14 illustrates a cross-sectional view of a filament according toanother embodiment.

DETAILED DESCRIPTION

The compositions and methods of the appended claims are not limited inscope by the specific compositions and methods described herein, whichare intended as illustrations of a few aspects of the claims, and anycompositions and methods that are functionally equivalent are intendedto fall within the scope of the claims. Various modifications of thecompositions and methods in addition to those shown and described hereinare intended to fall within the scope of the appended claims. Variousmodifications of the compositions and methods in addition to those shownand described herein are intended to fall within the scope of theappended claims. Further, while only certain representative compositionsand method steps disclosed herein are specifically described, othercombinations of the compositions and method steps are also intended tofall within the scope of the appended claims, even if not specificallyrecited. Thus, a combination of steps, elements, components, orconstituents may be explicitly mentioned herein; however, othercombinations of steps, elements, components, and constituents areincluded, even though not explicitly stated.

The term “comprising” and variations thereof as used herein is usedsynonymously with the term “including” and variations thereof and areopen, non-limiting terms. Although the terms “comprising” and“including” have been used herein to describe various embodiments, theterms “consisting essentially of” and “consisting of” can be used inplace of “comprising” and “including” to provide more specificembodiments of the invention and are also described. Other than in theexamples, or where otherwise noted, all numbers expressing quantities ofingredients, reaction conditions, and so forth used in the specificationand claims are to be understood at the very least, and not as an attemptto limit the application of the doctrine of equivalents to the scope ofthe claims, to be construed in light of the number of significant digitsand ordinary rounding approaches.

As used in the specification and the appended claims, the singular forms“a”, “an” and “the” include plural referents unless the context clearlydictates otherwise.

“Optional” and “optionally” means that the subsequently described eventor circumstance may or may not occur, and that the description includesinstances where said event or circumstance occurs and instances where itdoes not.

Yarns and multi-component filaments having a plurality of solidparticles dispersed throughout a portion of the filaments are describedherein. Inclusion of solid particles through a portion of the filamentsallows for differing certain properties in products formed from thefilaments while maintaining desirable physical properties such asstrength or abrasion resistance. For example, including translucent ortransparent particles, such as glass flakes or mica, may differ thevisual properties, such as providing an increased luster. And, in otherimplementations, opaque solid particles may be included through aportion of the filaments to create a different property for a productformed with the filament.

Thus according to a first aspect, a multi-component filament is providedcomprising a first component comprising a first polymer and a secondcomponent comprising a second polymer and a plurality of solid particlesdispersed within the second polymer, wherein the second componentdefines at least 50 percent of an external (or outermost) surface areaof the multi-component filament. In some embodiments, themulti-component filament is a bicomponent filament.

A cross-sectional shape of the multi-component filaments describedherein may be round or may have other shapes, such as octalobal, delta,sunburst (also known as sol), scalloped oval, trilobal, tetra-channel(also known as quatra-channel), kidney, scalloped ribbon, ribbon,starburst, semicircular, and the like. The cross-sectional shape refersto the shape of the filament as viewed in a plane that extendsperpendicular to a central axis of the filament (e.g., an end view ofthe filament). The filaments may be solid, hollow, or multi-hollow(e.g., defining one or more axial voids therethrough).

FIGS. 1-2 and 4-14 illustrate cross-sectional views of bicomponentfilaments having first and second polymers with different arrangementswith respect to each other, in accordance with various embodiments ofthe first aspect. As shown, the second component comprises the secondpolymer and the plurality of solid particles dispersed therein anddefines at least 50 percent of an external (or outermost) surface areaof the bicomponent filament.

For example, FIG. 1 illustrates a bicomponent filament 120 that has atrilobal cross-sectional shape and includes a first component 122 and asecond component 124. The first component 122 forms a core and is fullyencapsulated by the second component 124. The first component 122includes the first polymer, and the second component 124 includes thesecond polymer 124 a and the plurality of solid particles 124 bdispersed within the second polymer 124 a. However, in other embodimentsin accordance with the first aspect, the first component may not befully encapsulated by the second component.

The bicomponent filament 130 shown in FIG. 2 also has a trilobalcross-sectional shape and includes first component 132 and secondcomponent 134. The second component 134 defines the trilobal shapedfilament, and strands of the first component 132 are coupled to distalends of each lobe of the second component 134. The first component 132includes the first polymer, and the second component 134 includes thesecond polymer 134 a and the plurality of solid particles 134 bdispersed within the second polymer 134 a. The strands of the firstcomponent 132 have a circular cross-sectional shape, but in otherembodiments in accordance with the first aspect, the strands of thefirst component may have another cross-sectional shape, such as any ofthose described herein.

FIG. 4 illustrates another example of a core/sheath bicomponent filament10. The first component 12 comprises a core and the second component 14comprises a sheath that fully encapsulates the core. The first component12 and the second component 14 both have circular cross-sectionalshapes, and the first component 12 is centered within the volume of thesecond component 14. The first component 12 includes the first polymer,and the second component 14 includes the second polymer 14 a and theplurality of solid particles 14 b dispersed within the second polymer 14a.

The core/sheath bicomponent filament 20 in FIG. 5 is similar to thefilament 10 in FIG. 4 in that the first component 22 is fullyencapsulated by the second component 24 and components 12, 14 havecircular cross-sectional shapes, but the first component 22 is notcentered within the volume of the second component 24. The firstcomponent 22 includes the first polymer, and the second component 24includes the second polymer 24 a and the plurality of solid particles 24b dispersed within the second polymer 24 a.

The filaments 10, 20 have a circular cross-sectional shape, but in otherembodiments in accordance with the first aspect, the filaments may haveother cross-sectional shapes, such as those described herein. Inaddition, these filaments 10, 20 have a circular shaped first component12, 22 as viewed in the plane that extends perpendicular to the centralaxis of the filament 10, 20, but the first components in otherembodiments in accordance with the first aspect may have othercross-sectional shapes, such as those described herein, and/or maydefine one or more voids therethrough.

As another example, in the bicomponent filament 30 shown in FIG. 6 , thefirst component 32 and the second component 24 have a semi-circularshaped cross-section and are coupled together along flat surfaces ofeach component 32, 34 along a plane that includes the central axis ofthe filament. An external surface of the filament 30 has a circularcross-sectional shape. The first component 32 includes the firstpolymer, and the second component 34 includes the second polymer 34 aand the plurality of solid particles 34 b dispersed within the secondpolymer 34 a. In other embodiments in accordance with the first aspect,the volume of the second component 34 in the filament may be increasedrelative to the first component 32 such that the plane along which thecomponents are coupled is spaced apart from the plane that includes thecentral axis.

As another example, a cross-sectional shape of the external surface ofthe bicomponent filament 40 shown in FIG. 7 follows the external contourof the number 8. The first component 42 and the second component 44 eachhave a partial circular cross-sectional shape, and the components 42, 44are coupled together along a plane that includes a chord of eachcross-section, wherein the chord has a length that is less than adiameter of each component 42, 44. The plane in which the components 42,44 are coupled includes a central axis of the filament 40. The firstcomponent 42 includes the first polymer, and the second component 44includes the second polymer 44 a and the plurality of solid particles 44b dispersed within the second polymer 44 a. In other embodiments inaccordance with the first aspect, the plane in which the components 42,44 are coupled may be spaced apart from the central axis of thefilament.

The bicomponent filament 50 shown in FIG. 8 is similar to the filament30 shown in FIG. 6 but defines a circular shaped axial void 56 that iscentered within the filament 50, as viewed in the plane that extendsperpendicular to a central axis of the filament 50. The first component52 includes the first polymer, and the second component 54 includes thesecond polymer 54 a and the plurality of solid particles 54 b dispersedwithin the second polymer 54 a.

The bicomponent filament 60 shown in FIG. 9 is similar to thebicomponent filament 50 in FIG. 8 , but the circular-shaped void 66 isnot centered within the filament 60. The first component 62 includes thefirst polymer, and the second component 64 includes the second polymer64 a and the plurality of solid particles 64 b dispersed within thesecond polymer 64 a.

The bicomponent filament 70 shown in FIG. 10 has a circularcross-sectional shape and defines an axial void 76 that is centered inthe filament. The first component 72 and the second component 74 arearranged circumferentially around the central axis of the filament inalternating radial segments. For example, the filament 70 has sixteenradial segments, wherein the first component 72 and the second component74 are alternately arranged around the central axis and void 76 of thefilament 70. The first component 72 includes the first polymer, and thesecond component 74 includes the second polymer 74 a and the pluralityof solid particles 74 b dispersed within the second polymer 74 a. Inother embodiments in accordance with the first aspect, the filament canhave four or more alternating segments of the first and secondcomponents and no axial voids or more than one axial voids. For example,the bicomponent filament 80 in FIG. 11 shows an example of a bicomponentfilament 80 having no axial voids but includes the circumferentialarrangement of the first component 82 and the second component 84 inalternating radial segments. The first component 82 includes the firstpolymer, and the second component 84 includes the second polymer 84 aand the plurality of solid particles 84 b dispersed within the secondpolymer 84 a. In addition, the angle of each segment in the filaments70, 80 are the same, but in other embodiments in accordance with thefirst aspect, the angle of each segment may be varied relative to theother segments to increase the amount of surface area on the exteriorsurface of the filament.

The bicomponent filament 90 shown in FIG. 12 has a circularcross-sectional shape and includes alternating chord segments of thefirst component 92 and the second component 94. For example, thefilament 90 has seven segments, but in other embodiments in accordancewith the first aspect, the filament may have two or more alternatingchord segments. The segments of filament 90 may have equal widths (asmeasured along a diameter of the filament 90) or the segments may haveunequal widths to allow one of the components 92, 94 to occupy a greatersurface area of the exterior surface of the filament 90. The firstcomponent 92 includes the first polymer, and the second component 94includes the second polymer 94 a and the plurality of solid particles 94b dispersed within the second polymer 94 a.

The bicomponent filament 100 shown in FIG. 13 has a circularcross-sectional shape and includes a first component 102 and a secondcomponent 104. The first component 102 is mostly encapsulated by thesecond component 104 but a portion of the first component 102 extends tothe exterior surface of the filament 100. The first component 102includes the first polymer, and the second component 104 includes thesecond polymer 104 a and the plurality of solid particles 104 bdispersed within the second polymer 104 a.

The bicomponent filament 110 shown in FIG. 14 has a circularcross-sectional shape and includes first component 112 and secondcomponent 114. The first component 112 comprises multiple strandsextending axially through the second component 114, and the secondcomponent 114 encapsulates the first component 112 strands. Some of thestrands of the first component 112 are circumferentially arranged inrings 112 a-e, and the rings 112 a-e are radially spaced from each otherand centered with respect to a central strand 112 e, which extends alongthe central axis of the filament 110. The first component 112 includesthe first polymer, and the second component 114 includes the secondpolymer 114 a and the plurality of solid particles 114 b dispersedwithin the second polymer 114 a.

In other embodiments according to the first aspect, the filaments mayinclude more than two components and/or have any cross-sectional shape,including any of the shapes described herein.

A plurality of any of the multi-component filaments described herein maybe combined into a yarn according to the second aspect. For example, aplurality of any of the bicomponent filaments described herein may becombined into a yarn.

FIG. 3 shows a cross-section of filaments that are combined into a yarn140 according to one embodiment in accordance with the third aspect. Theyarn 140 includes a first set of filaments 142 comprising (e.g.,consisting of) the first polymer and a second set of filaments 144comprising (e.g., consisting of) the second polymer having solidparticles dispersed therein. Each filament has a tri-lobal shapedcross-sectional shape, but in other embodiments, one or more of thefilaments may have other cross-sectional shapes, such as those describedherein. The sets of filaments 142, 144 are combined together to form theyarn 140. The filaments from the second set of filaments define at leastfifty percent of the external surface area of the yarn 140.

In addition, in other embodiments in accordance with the third aspect,the filaments in each set may be single component or have two or morecomponents. And, in other embodiments in accordance with the thirdaspect, the cross-sectional shape of the first filaments and the secondfilaments can be the same or different, and the cross-sectional shape offilaments in each of set of filaments can be the same or different.

In some embodiments according to any of the first, second, or thirdaspect, the first polymer and the second polymer are the same, and inother embodiments, the first polymer and the second polymer aredifferent.

Example systems for spinning the multi-component filaments describedherein includes at least two extruders (e.g., an extruder correspondingto each component) and at least one spin pack that includes at least onespinneret that defines openings that form the cross-sectional shapes ofthe filaments spun therethrough.

Any of the embodiments described below in the specification can beapplied to any of the first through third aspects.

In some embodiments, the first polymer and the second polymer mayindependently comprise a polymer selected from a polyamide, a polyester,or a polyolefin. In some embodiments, the first polymer and the secondpolymer comprise the same polymer. In some embodiments, the firstpolymer comprises a polyamide and the second polymer comprises apolyester. In some embodiments, the first polymer comprises a polyamideand the second polymer comprises a polyolefin. In some embodiments, thefirst polymer comprises a polyester and the second polymer comprises apolyamide. In some embodiments, the first polymer comprises a polyesterand the second polymer comprises a polyolefin. In some embodiments, thefirst polymer comprises a polyolefin and the second polymer comprises apolyamide. In some embodiments, the first polymer comprises a polyolefinand the second polymer comprises a polyester. In some embodiments, thefirst polymer and the second polymer each independently comprise apolyamide, either the same polyamide or two different polyamides. Insome embodiments, the first polymer and the second polymer eachindependently comprise a polyester, either the same polyester or twodifferent polyesters. In some embodiments, the first polymer and thesecond polymer each independently comprise a polyolefin, either the samepolyolefin or two different polyolefins.

A polyamide is defined as a synthetic linear polymer whose repeatingunit contains amide functional groups, wherein these amide functionalgroups are integral members of the linear polymer chain.

In some embodiments, the polyamide may have been formed by condensationpolymerization of a dicarboxylic acid and a diamine Representativeexamples of such dicarboxylic acids include terephthalic acid,isophthalic acid, 2,6-napthalene dicarboxylic acid, 3,4′-diphenyletherdicarboxylic acid, hexahydrophthalic acid, 2,7-naphthalenedicarboxylicacid, phthalic acid, 4,4′-methylenebis(benzoic acid), oxalic acid,malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipicacid, 3-methyladipic acid, pimelic acid, suberic acid, azelaic acid,sebacic acid, 1,11-undecanedicarboxylic acid, 1,10-dodecanedicarboxylicacid, 1,12-dodecanedicarboxylic acid, hexadecanedioic acid,docosanedioic acid, tetracosanedioic acid, 1,4-cyclohexanedicarboxylicacid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanediactic acid,fumaric acid, and maleic acid. Representative examples of such diaminesinclude ethylene diamine, tetramethylene diamine, hexamethylene diamine,1,9-nonanediamine, 2-methyl pentamethylene diamine, trimethylhexamethylene diamine (TMD), m-xylylene diamine (MXD), and1,5-pentanediamine.

In some embodiments, the polyamide may have been formed by condensationpolymerization of an amino acid (such as 11-aminoundecanoic acid) orring-opening polymerization of a lactam (such as caprolactam orw-aminolauric acid).

Representative examples of polyamides as may be used in the presentdisclosure include: aliphatic polyamides such as polyamide 6, polyamide11, polyamide 12, polyamide 46, polyamide 410, polyamide 4T, polyamide510, polyamide D6, polyamide DT, polyamide DI, polyamide 66, polyamide610, polyamide 612, polyamide 6T, polyamide 6I, polyamide MXD6,polyamide 9T, polyamide 1010, polyamide 10T, polyamide 1212, polyamide12T, polyamide PACM12, polyamide TMDT, polyamide 611, and polyamide1012; polyphthalimides such as polyamide 6T/66, polyamide LT/DT, andpolyamide L6T/6I; and aramid polymers.

A polyester is defined as a synthetic linear polymer whose repeatingunits contain ester functional groups, wherein these ester functionalgroups are integral members of the linear polymer chain.

Typical polyesters as used in the present disclosure may be formed bycondensation of a dicarboxylic acid and a diol. Representative examplesof such dicarboxylic acids include terephthalic acid, isophthalic acid,2,6-naphthalene dicarboxylic acid, 3,4′-diphenylether dicarboxylic acid,hexahydrophthalic acid, 2,7-napthalene dicarboxylic acid, phthalic acid,4,4′-methylenebis(benzoic acid), oxalic acid, malonic acid, succinicacid, methyl succinic acid, glutaric acid, adipic acid, 3-methyladipicacid, pimelic acid, suberic acid, azelaic acid, sebacic acid,1,11-undecanedicarboxylic acid, 1,10-dodecanedicarboxylic acid,1,12-dodecanedicarboxylic acid, hexadecanedioic acid, docosanedioicacid, tetracosanedioic acid, 1,4-cyclohexanedicarboxylic acid,1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanediacetic acid, fumaricacid, and maleic acid. Representative examples of such diols includemonoethylene glycol, diethylene glycol, triethylene glycol,poly(ethylene ether)glycols, 1,3-propanediol, 1,4-butanediol,poly(butylene ether)glycols, pentamethylene glycol, 1,6-hexanediol,1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol,1,14-tetradecanediol, 1,16-hexadecanediol,cis-1,4-cyclohexanedimethanol, and trans-1,4-cyclohexanedimethanol.

Representative examples of polyesters include poly(ethyleneterephthalate) (PET), poly(trimethylene terephthalate) (PTT),poly(butylene terephthalate) (PBT), poly(ethylene isophthalate),poly(octamethylene terephthalate), poly(decamethylene terephthalate),poly(pentamethylene isophthalate), poly(butylene isophthalate),poly(hexamethylene isophthalate), poly(hexamethylene adipate),poly(pentamethylene adipate), poly(pentamethylene sebacate),poly(hexamethylene sebacate), poly(1,4-cyclohexylene terephthalate),poly (1,4-cyclohexylene sebacate), poly(ethyleneterephthalate-co-sebacate), and poly(ethylene-co-tetramethyleneterephthalate).

A polyolefin comprises a polymer formed from a simple olefin as amonomer. Representative examples of polyolefins which may be used in thepresent disclosure include, but are not limited to, polyethylene orpolypropylene.

In some embodiments, the first polymer comprises polyamide 6 and thesecond polymer comprises polyethylene terephthalate. In someembodiments, the first polymer comprises polyamide 6 and the secondpolymer comprises polytrimethylene terephthalate. In some embodiments,the first polymer comprises polyamide 6 and the second polymer comprisespolyethylene. In some embodiments, the first polymer comprises polyamide6 and the second polymer comprises polypropylene. In some embodiments,the first polymer comprises polyamide 6,6 and the second polymercomprises polyethylene terephthalate. In some embodiments, the firstpolymer comprises polyamide 6,6 and the second polymer comprisespolytrimethylene terephthalate. In some embodiments, the first polymercomprises polyamide 6,6 and the second polymer comprises polyethylene.In some embodiments, the first polymer comprises polyamide 6,6 and thesecond polymer comprises polypropylene.

In some embodiments, the first polymer comprises polyethyleneterephthalate and the second polymer comprises polyamide 6. In someembodiments, the first polymer comprises polyethylene terephthalate andthe second polymer comprises polyamide 6,6. In some embodiments, thefirst polymer comprises polyethylene terephthalate and the secondpolymer comprises polyethylene. In some embodiments, the first polymercomprises polyethylene terephthalate and the second polymer comprisespolypropylene. In some embodiments, the first polymer comprisespolytrimethylene terephthalate and the second polymer comprisespolyamide 6. In some embodiments, the first polymer comprisespolytrimethylene terephthalate and the second polymer comprisespolyamide 6,6. In some embodiments, the first polymer comprisespolytrimethylene terephthalate and the second polymer comprisespolyethylene. In some embodiments, the first polymer comprisespolytrimethylene terephthalate and the second polymer comprisespolypropylene.

In some embodiments, the first polymer comprises polyethylene and thesecond polymer comprises polyamide 6. In some embodiments, the firstpolymer comprises polyethylene and the second polymer comprisespolyamide 6,6. In some embodiments, the first polymer comprisespolyethylene and the second polymer comprises polyethyleneterephthalate. In some embodiments, the first polymer comprisespolyethylene and the second polymer comprises polytrimethyleneterephthalate. In some embodiments, the first polymer comprisespolypropylene and the second polymer comprises polyamide 6. In someembodiments, the first polymer comprises polypropylene and the secondpolymer comprises polyamide 6,6. In some embodiments, the first polymercomprises polypropylene and the second polymer comprises polyethyleneterephthalate. In some embodiments, the first polymer comprisespolypropylene and the second polymer comprises polytrimethyleneterephthalate.

In some embodiments, the first polymer and the second polymer eachcomprise polyamide 6. In some embodiments, the first polymer and thesecond polymer each comprise polyamide 6,6. In some embodiments, thefirst polymer comprises polyamide 6 and the second polymer comprisespolyamide 6,6. In some embodiments, the first polymer comprisespolyamide 6,6 and the second polymer comprises polyamide 6.

In some embodiments, the first polymer and the second polymer eachcomprise polyethylene terephthalate. In some embodiments, the firstpolymer and the second polymer each comprise polytrimethyleneterephthalate. In some embodiments, the first polymer comprisespolyethylene terephthalate and the second polymer comprisespolytrimethylene terephthalate. In some embodiments, the first polymercomprises polytrimethylene terephthalate and the second polymercomprises polyethylene terephthalate.

In some embodiments, the first polymer and the second polymer eachcomprise polyethylene. In some embodiments, the first polymer and thesecond polymer each comprise polypropylene. In some embodiments, thefirst polymer comprises polyethylene and the second polymer comprisespolypropylene. In some embodiments, the first polymer comprisespolypropylene and the second polymer comprises polyethylene.

In one aspect, a plurality of solid particles are dispersed within thesecond polymer. In some embodiments, the first component may furthercomprise a plurality of solid particles dispersed in the first polymer,the plurality of solid particles having a concentration by volume in thefirst polymer that is less than a concentration by volume of theparticles of the second polymer. In some embodiments, the solidparticles are evenly dispersed in the first polymer. In someembodiments, the plurality of solid particles have a concentrationvolume in the first polymer that is 10% less, 20% less, 30% less, 40%less, 50% less, 60% less, 70% less, 80% less, or 90% less than theconcentration by volume of the particles in the second polymer. In otherembodiments, the first component does not comprise solid particlesdispersed in the first polymer.

In some embodiments, the solid particles may have an average particlediameter ranging from 5 microns to 35 microns, for example from 5 micronto 30 microns, from 5 microns to 25 microns, from 5 microns to 20microns, from 5 microns to 15 microns, from 5 microns to 10 microns,from 10 microns to 35 microns, from 10 microns to 30 microns, from 10microns to 25 microns, from 10 microns to 20 microns, from 10 microns to15 microns, from 15 microns to 35 microns, from 15 microns to 30microns, from 15 microns to 25 microns, from 15 microns to 20 microns,from 20 microns to 35 microns, from 20 microns to 30 microns, from 20microns to 25 microns, from 25 microns to 35 microns, from 25 microns to30 microns, or from 30 microns to 35 microns. In some embodiments, thesolid particles may have an average particle diameter of 5 microns, 6microns, 7 microns, 8 microns, 9 microns, 10 microns, 11 microns, 12microns, 13 microns, 14 microns, 15 microns, 16 microns, 17 microns, 18,microns, 19 microns, 20 microns, 21 microns, 22 microns, 23 microns, 24microns, 25 microns, 26 microns, 27 microns, 28 microns, 29 microns, 30microns, 31 microns, 32 microns, 33 microns, 34 microns, or 35 microns.

In some embodiments, the solid particles may comprise glass flakes. Insome embodiments, the glass flakes may comprise E-glass, C-glass,E-CR-glass, or combinations thereof. “E-glass” refers toalumino-borosilicate glass having less than 1% alkali oxides by weight.“C-glass” refers to alkali-lime glass with a high boron oxide content.“E-CR-glass” refers to alumino-lime silicate glass with less than 1%alkali oxides by weight.

In some embodiments, the glass flakes may have an average particlediameter ranging from 5 microns to 35 microns, for example from 5 micronto 30 microns, from 5 microns to 25 microns, from 5 microns to 20microns, from 5 microns to 15 microns, from 5 microns to 10 microns,from 10 microns to 35 microns, from 10 microns to 30 microns, from 10microns to 25 microns, from 10 microns to 20 microns, from 10 microns to15 microns, from 15 microns to 35 microns, from 15 microns to 30microns, from 15 microns to 25 microns, from 15 microns to 20 microns,from 20 microns to 35 microns, from 20 microns to 30 microns, from 20microns to 25 microns, from 25 microns to 35 microns, from 25 microns to30 microns, or from 30 microns to 35 microns. In some embodiments, theglass flakes have an average particle diameter of 5 microns, 6 microns,7 microns, 8 microns, 9 microns, 10 microns, 11 microns, 12 microns, 13microns, 14 microns, 15 microns, 16 microns, 17 microns, 18, microns, 19microns, 20 microns, 21 microns, 22 microns, 23 microns, 24 microns, 25microns, 26 microns, 27 microns, 28 microns, 29 microns, 30 microns, 31microns, 32 microns, 33 microns, 34 microns, or 35 microns. In someembodiments, the glass flakes may have an average diameter ranging from27 microns to 32 microns. In some embodiments, the glass flakes may havean average diameter ranging from 20 microns to 50 microns. In someembodiments, the glass flakes may have an average diameter ranging from8 microns to 12 microns.

In some embodiments, the glass flakes may have an average thicknessranging from microns to 8 microns, for example 0.5 microns to 7 microns,0.5 microns to 6 microns, 0.5 microns to 5 microns, 0.5 microns to 4microns, 0.5 microns to 3 microns, 0.5 microns to 2 microns, 0.5 micronsto 1 micron, 1 micron to 8 microns, 1 micron to 7 microns, 1 micron to 6microns, 1 micron to 5 microns, 1 micron to 4 microns, 1 micron to 3microns, 1 micron to 2 microns, 2 microns to 8 microns, 2 microns to 7microns, 2 microns to 6 microns, 2 microns to 5 microns, 2 microns to 4microns, 2 microns to 3 microns, 3 microns to 8 microns, 3 microns to 7microns, 3 microns to 6 microns, 3 microns to 5 microns, 3 microns to 4microns, 4 microns to 8 microns, 4 microns to 7 microns, 4 microns to 6microns, 4 microns to 5 microns, 5 microns to 8 microns, 5 microns to 7microns, 5 microns to 6 microns, 6 microns to 8 microns, 6 microns to 7microns, or 7 microns to 8 microns. In some embodiments, the glassflakes may have an average thickness of 0.5 microns, 0.6 microns, 0.7microns, 0.8 microns, 0.9 microns, 1 micron, 1.2 microns, 1.4 microns,1.6 microns, 1.8 microns, 2.0 microns, 2.2 microns, 2.4 microns, 2.6microns, 2.8 microns, 3.0 microns, 3.2 microns, 3.4 microns, 3.6microns, 3.8 microns, 4.0 microns, 4.2 microns, 4.4 microns, 4.6microns, 4.8 microns, 5.0 microns, 5.2 microns, 5.4 microns, 5.6microns, 5.8 microns, 6.0 microns, 6.2 microns, 6.4 microns, 6.6microns, 6.8 microns, 7.0 microns, 7.2 microns, 7.4 microns, 7.6microns, 7.8 microns, or 8.0 microns.

In some embodiments, the glass flakes comprise E-glass flakes having anaverage diameter ranging from 27 microns to 32 microns and an averagethickness ranging from 0.9 microns to 1.3 microns. In some embodiments,the glass flakes comprise E-glass flakes having an average diameterranging from 27 microns to 32 microns and an average thickness rangingfrom 3 microns to 7 microns.

In some embodiments, the glass flakes comprise C-glass flakes having anaverage diameter ranging from 20 microns to 50 microns and an averagethickness ranging from 3 microns to 7 microns.

In some embodiments, the glass flakes comprise E-CR-glass flakes havingan average diameter ranging from 27 microns to 32 microns and an averagethickness ranging from 0.9 microns to 1.3 microns. In some embodiments,the glass flakes comprise E-CR-glass flakes having an average diameterranging from 8 microns to 12 microns and an average thickness rangingfrom 0.9 microns to 1.3 microns. In some embodiments, the glass flakescomprise E-CR-glass flakes having an average diameter ranging from 27microns to 32 microns and an average thickness ranging from 2.3 micronsto 3.3 microns. In some embodiments, the glass flakes compriseE-CR-glass flakes having an average diameter ranging from 27 microns to32 microns and an average thickness ranging from 4 microns to 6 microns.

In some embodiments, the solid particles may comprise mica particles.Typically, the mica particles comprise ground mica, for examplewet-ground mica which maintains the brilliance of the cleavage faces ofthe sheet material. The mica particles as used in the present disclosuremay comprise muscovite, paragonite, biotite, lepidolite, phlogopite,zinnwaldite, clintonite, hydro-muscovite, illite, phengite, or sericite.

In some embodiments, the solid particles, for example glass flakes ormica particles, may be surface treated with a coating prior to beingdispersed within the second polymer. This coating can reduce theabrasiveness of the solid particles. In some embodiments, the coatingcomprises a silane coating. Representative examples of silane coatingswhich may be used in the present disclosure include, but are not limitedto, 3-aminopropyltriethoxysilane, vinyltrimethoxysilane,3-glycidoxypropyltrimethoxysilane, or3-methacryloxypropyltrimethoxysilane.

In some embodiments, the solid particles, for example glass flakes ormica particles, may have a concentration of at least 10% by volumewithin the second polymer. In some embodiments, the solid particles, forexample glass flakes, may have a concentration of 10%, 15%, 20%, 25%,30%, 35% or 40% by volume within the second polymer.

In some embodiments, the filaments may further comprise one or moreadditives including, but limited to: flame retardant additives, forexample decabromodiphenyl ether and triarylphosphates such as triphenylphosphate; reinforcing agents; thermal stabilizers, for example thermalconductivity improvers such as zinc oxide and titanium oxide;ultraviolet light stabilizers such as resorcinol monobenzoates, phenylsalicylate and 2-hydroxybenzophenones; hindered amine stabilizers suchas benzotriazole, benzophenone, oxalanilide, and cerium oxide; impactmodifiers; flow enhancing additives; ionomers; liquid crystal polymers;fluoropolymers; olefins including cyclic olefins; polyamides; ethylenevinyl acetate copolymers; stabilizing agents such as ortho-phosphoricacid, triphenylphosphate, and triethylphosphino acetate; delusteringagents such as titanium oxide; carriers such as o-phenylphenol,p-phenylphenol, o-dichlorobenzene, trichlorobenzene, monochlorobenzene,biphenyl, methyl salicylate, butyl benzoate, benzyl benzoate, benzoicacid, benzalacetone, and methyl cinnamate; leveling agents such asbishydroxymethyloxazoline, diaryl ethers, ditolyl ether, sodiumdi-naphthylmethane-B,B-disulfonate, ammonium dodecylbenzene sulfonate,sodium tetrapropylbenzene sulfonate, homopolymers or oligomers ofN-vinylpyrrolidone and poly(tetrahydrofuran); and porosity additivessuch as metal oxalate complexes, organic sulfonate salts, jade powder,and zeolite powder.

In some embodiments according to any of the first through third aspects,the multi-component filament or yarn may have a luster greater than amulti-component filament or yarn that comprises the first polymer andthe second polymer without the solid particles. “Luster” refers to thebrightness or sheen of the filament and is associated with the degree oflight that is reflected from the surface of the filament or the degreeof gloss or sheen that the filament possesses. The inherent chemical andphysical structure and shape of the fiber can affect the relative lusterof the filament. Synthetic filaments may be characterized by a varietyof luster classifications, such as bright, semi-bright, semi-dull, andmid-dull, and the luster can be influenced by heat setting, dyeing, orfinishing of any fibers formed from the filaments. Luster results fromthe way light is reflected from the surface. The more lustrous a fiber,the more evenly it reflects incident light.

Luster may be measured by any number of commercially availablelustermeters as would be known to one skilled in the art. With suchinstruments, luster is measured as the contrast and ratio between thespecular reflectance and the diffuse reflectance. The specularreflectance factor can be expressed as R_(S) (45°/45° gloss), and thediffuse reflectance factor expressed as R_(D) (45°/0° diffusereflectance). Reflectance indicates the degree of diffuse light at 90degrees to the filament surface with the incident light at 45 degrees tothe filament surface. The angle between the light source and detector is45 degrees. Gloss designates the degree of light measured at 45 degreesto the filament surface with the incident light again at 45 degrees tothe filament surface. The angle between the light source and thedetector is 90 degrees. Luster is calculated from the ratio of Gloss toReflectance as follows: Luster=100−(4.5)=(R_(D)/R_(S)).

Also provided are manufactured products, such as textiles includingcarpets, produced using a filament or yarn of any one of the firstthrough third aspects described herein.

A number of embodiments of the disclosure have been described.Nevertheless, it will be understood that various modifications may bemade without departing from the spirit and scope of the invention.Accordingly, other embodiments are within the scope of the followingclaims.

1.-77. (canceled)
 78. A multi-component filament comprising: a firstcomponent comprising a first polymer; and a second component comprisinga second polymer and a plurality of transparent or translucent solidparticles evenly dispersed within the second polymer; wherein the secondcomponent defines at least 50 percent of an external surface area of themulti-component filament.
 79. The multi-component filament of claim 78,wherein the first component comprises a plurality of transparent ortranslucent solid particles dispersed in the first polymer, wherein theplurality of solid particles have a concentration by volume in the firstpolymer that is less than a concentration by volume of the solidparticles in the second polymer.
 80. The multi-component filament ofclaim 79, wherein the first polymer consists of a polymer selected fromthe group of a polyamide, a polyester, and a polyolefin.
 81. Themulti-component filament of claim 80, wherein the second polymerconsists of a polymer selected from the group of a polyamide, apolyester, and a polyolefin.
 82. The multi-component filament of claim81, wherein the solid particles comprise an average particle diameterranging from 5 microns to 35 microns and an average thickness rangingfrom 0.5 microns to 8 microns.
 83. The multi-component filament of claim82, wherein the solid particles are selected from a group consisting ofglass and mica.
 84. The multi-component filament of claim 83, whereinthe solid particles have been treated with a silane coating comprising asilate coupling reagent selected from the group consisting of3-aminopropyltriethoxysilane, vinyltrimethoxysilane,3-glycidoxypropyltrimethoxysilane, and3-methacryloxypropyltrimethoxysilane.
 85. The multi-component filamentof claim 84, wherein the solid particles have a concentration of atleast 10% by volume within the second polymer.
 86. The multi-componentfilament of claim 85, wherein a cross-sectional shape of themulti-component filament is configured to be selected from a groupconsisting of round, octalobal, delta, sunburst, scalloped oval,trilobal, tetra-channel, kidney, scalloped ribbon, ribbon, starburst,and semicircular.
 87. The multi-component filament of claim 86, whereinthe first polymer and the second polymer are the same.
 88. A yarncomprising at least one of a first filament and at least one of a secondfilament; wherein the first filament comprises a first polymer; andwherein the second filament comprises a second polymer and a pluralityof solid particles evenly dispersed within the second polymer.
 89. Theyarn of claim 88, wherein the first polymer consists of a polymerselected from the group of a polyamide, a polyester, and a polyolefin.90. The yarn of claim 89, wherein the second polymer consists of apolymer selected from the group of a polyamide, a polyester, and apolyolefin.
 91. The yarn of claim 90, wherein the solid particles aretransparent or translucent.
 92. The yarn of claim 91, wherein the atleast one first filament comprises a plurality of first filaments, andthe at least one second filament comprises a plurality of secondfilaments, and wherein the plurality of second filaments define at least50 percent of an external surface area of the yarn.
 93. The yarn ofclaim 92, wherein the solid particles comprise wet-ground mica particlesselected from the group consisting of muscovite, paragonite, biotite,lepidolite, phlogopite, zinnwaldite, clintonite, hydro-muscovite,illite, phengite, or sericite.
 94. The yarn of claim 92, wherein thesolid particles comprise glass flakes having an average particlediameter ranging from 5 microns to 35 microns, an average thicknessranging from microns to 8 microns, are comprised of E-glass, C-glass,E-CR-glass, or combinations thereof, and have been coated with a silanecoupling reagent selected from the group consisting of3-aminopropyltriethoxysilane, vinyltrimethoxysilane,3-glycidoxypropyltrimethoxysilane, and3-methacryloxypropyltrimethoxysilane.
 95. The yarn of claim 94, whereinthe glass flakes have a concentration of at least 10% by volume withinthe second polymer.
 96. The yarn of claim 95, wherein the first polymeris the same as the second polymer.
 97. A multi-component filamentcomprising: a first component comprising a first polymer with aplurality of solid particles evenly dispersed within the first polymer;and a second component comprising a second polymer and a plurality ofsolid particles evenly dispersed within the second polymer; wherein thesecond component defines at least 50 percent of an external surface areaof the multi-component filament; wherein the first and second polymersare each selected from the group consisting of a polyamide, a polyester,and a polyolefin; wherein the solid particles comprise glass flakes withan average particle diameter ranging from 5 microns to 35 microns and anaverage thickness ranging from 0.5 microns to 8 microns, and have beentreated with a silane coupling reagent selected from the groupconsisting of 3-aminopropyltriethoxysilane, vinyltrimethoxysilane,3-glycidoxypropyltrimethoxysilane, and3-methacryloxypropyltrimethoxysilane; and wherein the glass flakes havea concentration of at least 10% by volume within the second polymer.